Runs rough warm cold always. - Ford Powerstroke Diesel Forum
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  #1  
Old 01-25-2012, 10:32 AM
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Runs rough warm cold always.

I have been reading posts on several forums and have learned a lot so far. I have also asked on several forums but after buying the AE replies stopped. I have ideas but little cash. I want to verify failure before throwing what little money I have at the truck. Thanks for your patience and I hope we can figure this out.

So I started with going to Ford for my CPS recall. Truck immediately started running bad. Hate Dealers. Replaced new CPS took 10 minutes and 2 bandaids, still have no idea what cut my fingers.

Sputtering/ rough running is mostly noticed at idle to mid RPM 1500 range. High speed is smoother only due to rpms. There are sharp misses with almost a ping or knock each time. Motor sounds like it is running on 6 cylinders. I have read several posts most changed filter with short term success, ICP IPR and UVCH with limited success. Short of the shotgun approach I bought an AE scanner to keep from just R&R at random. I am retired and have time and several cars to drive for now. I want to do this right and replace only what needs replacing or is about time to replace due to mileage and convenience. If I pull valve covers I might as well replace glowplugs while I am open.....

I ran a few tests with AE. I ran a codes test and there were several old codes with overhead monitor, wipers and such. I ran KOEO and cleared with no hits. I ran KOER several times and got cleared most the time but once got P0272 CYL #4 Bal Fault???

The buzz test was 100% normal. All sounded similar and even.

I then monitored the motor with the following results

RPM 654...............ICP 487-495......................ICP DC 9.77
ACCPosit 10.2% ....EXBP 11.89........................ICP Volt 0.83
Eng Oil Temp 154...Vol Fuel 4.9........................FI Pulse 1.92

RPM 3100.............ICP 974.............................ICP DC 9.77
ACC Posit 30%......EXBP 21.............................ICP Volt 1.73
Eng Oil Temp 162...Vol Fuel 13.4.......................FI Pulse 1.55


When the throttle was WOT and climbing the ICP maxed at 1700 and the ACC Posit was 71% This is a little lower than the results should have been but does not explain the rough motor. I was really hoping to see much different results. I am tempted to believe the fuel tank is the only problem. If any one has an AE that wants to chime in and point the way I am humbly at your mercy.

I am leading towards needing the Hutch mod and cleaning the tank out. The results are very close to norm but fuel seems a bit low. I think a slight restriction on supply is causing the low HPOP results. I also filled the tank to eliminate the 1/4 tank air issues. I replaced the fuel filter under the hood.

Am I missing something? Is there better tests to run? I am pricing valve cover gaskets and UVCH just in case. I really do not want to throw away money. I just retired and am living on 60% of my pay now.


Truck has 148000 miles or so. Banks upgrades on turbo and wastegate. Someones chip was installed but it is old and no label left to ID it. I think it is a Hypermax chip. I have removed it for now to get to the bottom of problem solving. Truck has run like a striped ape pulling crazy loads when I wanted and passing Porsches and Mustangs like they were Gremlins and Pintos. This is new to the last 200 miles and getting worse by the 20 mile increments. I am now concerned with driving more than a few miles from home, let alone pulling any load at all.
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Old 01-26-2012, 01:33 AM
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I am a firm believer in eying the wires that go to wastegate, fuel heater, IPR, ICP, etc..special attention to where the wires emerge from the protective sleeves and point of plug attachment.

I had a no start problem and was told camshaft sensor...replaced it and no go still...turns out it was multiple wiring breaks or almost breaks...resoldered and GO GO!

I had a similar problem to yours, once. Ran fine much of the time, but had a hitch that felt like a backfire/big miss. Power ebbed. Turns out it was the under the valve cover harness losing contact. There is a Ford fix for it...a clip that holds the harness tightly, I think.
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Old 01-26-2012, 01:58 PM
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Thanks for the tip. I have tested the heck out of it even with it sputtering and bucking it tests good. I still am thinking since electrically it tests good it must be a fuel delivery problem. Today I am crawling under the hood again to check the wires engine off and on.
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Old 01-26-2012, 06:46 PM
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i like you am having the same troubles. I have thrown uvc harnesses new injectors and an idm in and truck still runs rough, i am at a total loss on mine so if you have any luck please share and ill do the same. i have the #8 failing the contribution test and it is a 2 day old alliant. i am supposed to get gauges tomorrow to test fuel pressure and restriction, thats my last hope cause i am broke broke broke.
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Old 01-27-2012, 06:51 AM
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Today I will start dropping the tank and doing the Hutch Mod. I see this as the most likely repair and fortunately the least expensive. I am also changing the air filter early as it showed 3/4 used and was quiet dusty. Not sure where the extra dust came from but for $14 it too is a cheep fix. Minus the rubber fuel line the hutch mod has cost only $24 and my time. I will post again in 2 days.

If any others familiar with the AE tool and it's tests have any options on parameters or tests let me know, but I still do not see anything so bad it would cause this problem.
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Old 01-27-2012, 06:34 PM
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WOW 25 gallons out. Looks like another 10 still in there. Where to keep all this fuel??? Real slow siphonning with 1/8 inch tubing. Good thing I am retired and have lots of time.
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Old 01-28-2012, 10:29 AM
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Still trying to get rid of fuel to drop the tank. I tried hooking up the AE again and noted something different. With a new K&N Filter in the miss is much stronger between 1400 and 1700 RPM. I still hear a soft miss at idle and at high RPM but in the short range noted it is like a swift kick to the shin.

Anyone know what is happening with the ecm or anyother computers at this range? If it were a gasser with an old carb on it this is where the idle circuit changes to high RPM circuit.
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Old 01-29-2012, 10:47 AM
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I ended up putting a fuel gauge on mine at the bowl, when first started i was getting 50 psi. As i drove around the neighborhood it droped down as low as 30. i proceeded to put it on the highway at 55 mph i was below 5 psi. dropped the tank and to my surprise it was very clean. I blew all my lines out and am currently putting it back together. I think I am looking at replacing the supply pump.
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Old 02-03-2012, 08:17 PM
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Fuel gage installed and steady 60psi no matter what. Valve covers coming off as soon as I can lean over the motor all day.
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Old 02-11-2012, 11:42 AM
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Well weather and age has blessed me with a day under the hood. I cleaned out the valley of all the old oil. I pulled the left valve cover and inspected all the wires. So far everything is just dirty and oily. I pulled all the cooler tubes and am cleaning them up too checking all the sleeves for damage. Everything on the sleeves was real tight and sealed well. The wye pipe in the middle was gross so I pulled it all the way out so I can clean it up and some of the wiring too. I will resolder the EBPV mod so it is real neat and clean and add some wire wraps to bundle and protect the wires. If the afternoon goes well I will have the right valve cover off too.

I looked real close for the oil flow on the injectors. All I coulc find was this bad video to compare with.
. The info is great and the video informative but the oil flow is hard to see. I have a real steady flow equal on all injectors. So I figure either all 4 were bad or they were more likely good. I will try to post some photos later depending on how well I do today.

I am finding some loose wires from add ons like Exh Temp and the brake mod. Better solder should fix them. Could the brake mod have caused the miss?? The main bundle looks real clean and tight with no rubbing or chafing.
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